Enclosure for modular construction systems

ABSTRACT

A simple and fast solution over the current modular construction techniques does not require welding or having to plaster the heads of the connecting elements, while allowing the increase and reinforcement of their resistance to the wind in locations with exposure to extreme winds. An enclosure includes a number of panels formed by at least one multilayer outer piece, a multilayer inner piece, and an intermediate air chamber, wherein the outer pieces of each panel have transverse grooves and recesses located at the side edges thereof. The enclosure includes bracing metal bars coupled to the groove of the outer pieces. The enclosure further includes supporting metal bars coupled vertically in correspondence with the recesses of the outer pieces.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention pertains to the field of construction, and more particularly to industrialised modular construction systems for buildings.

The object of the present invention is an enclosure for industrialised modular construction systems that, besides being a simple and fast solution compared to current techniques, without the need for welding or having to plaster the heads of connecting elements, allows, at the same time, compliance with the wind resistance regulations.

Description of Related Art

Currently, industrialised modular construction has become well known and widespread, where from modules or standardised sections, buildings of all types are manufactured in advance far from their destination, usually in a workshop, factory or warehouse, to be moved afterwards to their final location for positioning and final assembly.

Nowadays, there is a great amount of scientific literature on the many benefits provided by modular construction in terms of speed of completion of construction, quality and safety concerns, while the set of costs, material waste and impact on the environment are significantly reduced.

However, years of experience in the field of modular construction has resulted in the detection of various problems and inconveniences that have not yet been given a truly effective and reliable solution. A list of some of these problems follows below:

-   -   Current systems require performing “welds” between the main         steel structure and the different pieces or battens, to which         the enclosures are then screwed.     -   The above point of screwing of the enclosures to the battens         required a later stage of “plastering” the heads of the         connecting elements for an optimal aesthetic finish.     -   These phases of welding and plastering each of the heads of the         connecting elements pose high time consumption for the         operators, with consequent more expensive labour costs.     -   In addition, current systems significantly limit the work of         architectural firms, mainly due to the low resistance of their         modules as they are not self-supporting, to the limitation of         their dimensions and to the limitation of their façade finishes.

SUMMARY OF THE INVENTION

The present invention solves the above-mentioned disadvantages by providing an enclosure for modular systems that, in addition to being a simpler and faster solution compared to current techniques, allows to avoid having to weld and having to plaster the heads of the connecting elements, which involved a longer work time.

In addition, the enclosure described herein provides a significant increase in its resistance to extreme wind conditions, thereby ensuring integrity and the optimum condition of the panels without any deterioration.

More specifically, the enclosure for modular systems, object of the invention, comprises a plurality of panels having a tongue and groove joint for engagement with each other. These panels are made of a multilayer outer piece, a multilayer inner piece, and an intermediate air chamber arranged between the outer and inner pieces.

Thus, the outer pieces of the panels have a transverse groove in the lower and upper edge of each outer piece and recesses located at the side edges thereof.

In addition, the enclosure of the invention comprises bracing metal bars coupled to the aforementioned groove of the outer pieces, which are located in a higher and lower position respectively of the enclosure, said metal bars remaining arranged at a level corresponding to the ceiling and/or floor of each floor or height of the modular construction system in question.

Moreover, the enclosure of the invention also comprises supporting metal bars, coupled vertically in correspondence with the aforementioned recesses of the outer pieces, and wherein each supporting metal bar is located in an intermediate position between each two columns of panels. This special arrangement and location of the supporting metal bars is what will allow significantly strengthening and increasing the resistance of the enclosure against the stress and forces of extreme wind.

On this point, it should also be noted that, with the enclosure of the present invention, the panels are connected and coupled together easily and with minimal time consumption while structural rigidity is provided, and which ensures that there are no joins between the different levels or floors of the modular construction system, or between the side connections.

Preferably, it is contemplated that the multilayer inner pieces can comprise a transverse wooden batten, arranged in an upper and/or lower end thereof, said wooden battens being arranged at a level corresponding to the ceiling and/or floor of each floor or height of the modular construction system. These wooden battens allow adding a further reinforcing element, helping the structural rigidity of the assembly, without assuming an appreciable increase in weight.

On the other hand, unlike the current façade finishes, another feature to note is that the enclosure described herein allows configuring all kinds of façade finished surfaces, including ventilated façades, with the same materials as traditional construction systems.

BRIEF DESCRIPTION OF THE DRAWINGS

To complete the description that is going to be made and to assist a better understanding of the invention's characteristics, according to a preferred practical embodiment thereof, accompanying as an integral part of said description is a set of drawings, where the following is represented, in an illustrative and non-limiting way:

FIG. 1 shows a perspective view of a modular construction system made up of enclosures of the present invention.

FIG. 2 shows an exploded view of the enclosure of the invention, where an intermediate supporting metal bar located between two columns of pre-made up panels can be seen.

FIG. 3 shows a detail view, where the connection between two overlapping panels at the point of intersection existing between two height levels, the bracing metal bars remaining coupled to the grooves of the outer pieces, is observed.

FIG. 4 shows a side view of FIG. 3, where second screwing means for secure attachment between the inner pieces and the wooden battens and some “L”-shaped metallic bars in turn attached to the lower end of some “U”-shaped beams can be seen. A side view of the bottom of the enclosure, particularly the intersection between the floor slab and the side wall is also shown.

FIG. 5 shows a top sectional view where the side connection between panels, the intermediate location of the supporting metal bar, and the meeting of the panels with two support pillars can be seen.

FIGS. 6A and 6B show respective top views, but in this case showing the meeting of two adjacent panels placed in a corner, with rectangular tubes and an intermediate pillar, respectively, between the two panels as structural elements.

FIG. 7 shows a view where the top of an inner piece, its corresponding wooden batten, and a self-supporting roof panel intended to be screwed on said inner piece is observed.

FIG. 8 shows a perspective view, where the internal configuration of the multilayer floor slab, according to a preferred embodiment, is shown.

FIG. 9 shows a side view of FIG. 8, where the various constituent layers of the floor slab, including in this embodiment a panel with heating-cooling floor can be more clearly seen.

DETAILED DESCRIPTION OF THE INVENTION

An example of a preferred embodiment of the invention is described below with reference to the above-cited figures, without limiting or reducing the scope of protection of the present invention.

A modular construction (100) made up by the enclosure (1) of the invention, and which comprises a plurality of panels (2) having a tongue and groove joint (50) at their upper, bottom and side edges, as shown in FIGS. 1 and 2, for coupling together to form a vertical column of panels (2), as depicted in FIG. 1, can be seen in FIG. 1.

More specifically, each of said panels (2) are formed in turn by a multilayer outer piece (10), a multilayer inner piece (20), and an intermediate air chamber (30) arranged between the outer and inner pieces (10, 20), as reflected in FIGS. 3 and 4. At this point, FIGS. 5, 6A and 6B should be mentioned where, in addition to the various components and inner pieces of the panels (2) cited above, a top view of the connection between two panels (2) can be seen, both laterally, as seen in FIG. 5, with a pair of structural pillars (110) and the meeting in corner of two adjacent panels (2) where, in this case, a pair of rectangular tubes (111), FIG. 6A, and an intermediate pillar (110), FIG. 6B, respectively, as structural elements, are shown.

According to a preferred embodiment, each one of the outer pieces (10) comprises: an OSB (“Oriented strand board”); an insulating core of extruded polystyrene XPS; and a façade finish.

On the other hand, the inner pieces (20) comprise: a machined layer of extruded polystyrene XPS to incorporate channels for different water or air ducts; a first oriented strand board OSB, an insulating core of extruded polystyrene XPS; a second oriented strand board OSB, and a sheet of plasterboard.

In FIG. 3 can be observed that the outer pieces (10) have a transverse groove (11) located in the lower and upper edge of each outer piece (10) and recesses (12) shown in FIG. 2 located in the side edges thereof, with said recesses (12) being especially useful in extreme wind conditions.

The enclosure (1) of the invention further comprises bracing metal bars (40A), shown more clearly in FIG. 2, and are coupled or partially inserted into the grooves (11) of the outer pieces (10), which are located in a higher and lower position with respect to the enclosure (1), said bracing metal bars (40A) remaining arranged at a level corresponding to the ceiling and/or floor of each floor or height of the modular construction system (100), see FIGS. 2 and 3. At this point, it should be noted that, although in FIGS. 2 to 4 an “L”-shaped profile of said bracing metal bars (40A) is shown, they can have other shapes and configurations depending on each application.

With respect to these bracing metal bars (40A), it is important to note that, in the case of having enclosures (1) whose façade is formed by panels (2) with a single vertical outer piece (10), which goes from the floor to the ceiling, as depicted in FIG. 2, it is provided that the upper bracing metal bar (40A) has first screwing means (70A) for a secure connection and attachment between said upper bracing metal bar (40A) and a “U”-shaped beam (45) arranged perpendicularly under said upper bracing metal bar (40A), with its side branches of the U facing inwards, i.e. towards the inner piece (20), as is clearly reflected in FIGS. 3 and 4. On the other hand, in the case of enclosures (1) formed by a plurality of sliding panels (2), each with their corresponding independent outer piece (10), as shown on the right side of FIG. 1, said screwing means are not necessary since the panel that will be located in the uppermost position of each column can slide between the panel and the immediately lower bracing metal bar.

The enclosure (1) of the invention further comprises supporting metal bars (60) shown in FIGS. 2 and 5, preferably of steel, particularly useful in cases of exposure to extreme wind and coupled vertically, corresponding with the recesses (12) of the outer pieces (10), and wherein each supporting metal bar (60) is located in an intermediate position between two columns of panels (2), as shown in FIG. 2. This feature allows strengthening and stiffening the whole assembly, providing greater resistance to the enclosure (1).

According to a preferred embodiment of the invention, shown in FIGS. 3, 4, and 7, the multilayer inner pieces (20) comprise a transverse wooden batten (21), arranged in an upper and/or lower end thereof, said wooden battens (21) being arranged at a level corresponding to the ceiling and/or floor of each floor or height of the modular construction system (100). These wooden battens (21) contribute even more, if possible, to a greater rigidity and structural support for the whole of the enclosure (1) assembly.

In addition, in this exemplary embodiment, the enclosure (1) further comprises self-supporting roof panels (80), shown in FIGS. 3, 4, 7 to 9, which are preferably comprised of: a first oriented strand board OSB; an insulating core of extruded polystyrene XPS, a second oriented strand board OSB; and a sheet of plasterboard. As used herein, by the term “self-supporting” should be understood the quality of said ceiling panels (80) to be able to support and withstand the weight of operators transiting above them in the assembly work at the final location of the building in question.

On the other hand, in FIG. 4 it can be seen that the enclosure (1) further comprises second screwing means (70B) for the solid connection between the inner piece (20), the wooden batten (21) and an “L”-shaped metal bar (40B) connected in turn to the lower end of the “U”-shaped beam (45) and housed within the air chamber (30); also said second screwing means (70B) acting for the connection between the self-supporting ceiling panel (80) and the wooden batten (21).

In FIGS. 8 and 9 it can be seen that the enclosure (1) also comprises a multilayer floor slab (90), which, in the present embodiment is made up of: a metal-rubber acoustic laminate (91) arranged on the upper end of each bracing metal bar (40A); a structural metal bar (92); a wooden board (93) arranged on the structural metal bar (92); an insulation layer (94), arranged in an immediately higher position with respect to wooden board (93); a panel with heating-cooling floor (95) located on the insulation layer (94); a layer of mortar (96) arranged on the panel with heating-cooling floor (95); and a floor finish (97).

Preferably, the enclosure (1) further comprises a plurality of corners (3), also known as “isocorners”, coupled to the corners of the enclosure (1), and that have side through holes (3A) to facilitate the tasks of hoisting and anchoring of the enclosure (1), usually with cranes.

Therefore, through the enclosure of the present invention a simple as well as a rapid solution is provided for the construction and raising of industrialised buildings, all without the need for welding, joins, or plastering of the different connecting elements, which favours a substantially more agile and fast mounting and assembly of the enclosures with respect to the current modular construction techniques. In addition, this enclosure allows implementing the whole range of façades types as well as finish materials thereof. In addition, thanks to the addition of vertical intermediate supporting metal bars, maximum structural rigidity of the whole of the enclosure is achieved, allowing to increase its resistance to loads and forces exerted by extreme wind conditions. 

What is claimed is:
 1. An enclosure for modular construction systems comprising a plurality of panels having a tongue and groove joint for coupling each other, wherein said panels are formed by a multilayer outer piece, a multilayer inner piece, and an intermediate air chamber arranged between the multilayer outer and inner pieces: wherein the multilayer outer piece has a transverse groove located in a lower and upper edge of the multilayer outer piece and recesses located at side edges of the multilayer outer piece; the enclosure comprises bracing metal bars, coupled to the transverse groove of the multilayer outer piece, which are located in a lower position than the enclosure, said bracing metal bars remaining arranged at a level corresponding to a ceiling and/or floor of each floor or height of the modular construction system; and the enclosure comprises supporting metal bars, coupled vertically in correspondence with the recesses of the multilayer outer pieces, each of the supporting metal bars is located in an intermediate position between each two columns of the panels.
 2. The enclosure according to claim 1, wherein the multilayer inner pieces comprise a transverse wooden batten, arranged in an upper and/or lower end of the multilayer inner pieces, said transverse wooden battens being arranged at a level corresponding to the ceiling and/or floor of each floor or height of the modular construction system.
 3. The enclosure according to claim 2, wherein further comprising self-supporting ceiling panels.
 4. The enclosure according to claim 3, wherein the self-supporting ceiling panels comprise: a first oriented strand board OSB, an insulating core extruded polystyrene XPS, a second oriented strand board OSB, and a sheet of plasterboard.
 5. The enclosure according to claim 1, wherein, in the case of having the panels with a single outer piece, the upper bracing metal bar has a first screwing means for attachment between said upper bracing metal bar and a “U”-shaped beam arranged perpendicularly under said upper bracing metal bar.
 6. The enclosure according to claim 2, wherein further comprising second screwing means for connection between the inner piece, the wooden batten and an “L”-shaped metal bar connected in turn to the lower end of the “U”-shaped beam and housed within the air chamber; as for the connection between the self-supporting ceiling panel and the wooden batten.
 7. The enclosure according to claim 1, wherein further comprising a multilayer floor slab.
 8. The enclosure according to claim 7, wherein the multilayer floor slab comprises: a metal-rubber acoustic laminate arranged on the upper end of each bracing metal bar, a structural metal bar, a wooden board disposed on the structural metal bar, an insulating layer, arranged in a position immediately above with respect to the wooden board, a panel with heating-cooling floor located on the insulating layer, a layer of mortar arranged on the panel with heating-cooling floor, and a floor finish.
 9. The enclosure according to claim 1, wherein the multilayer outer pieces comprise: an oriented strand board OSB, an insulating core of extruded polystyrene XPS, and a facade finish.
 10. The enclosure according to claim 1, wherein the multilayer inner pieces comprise: a machined layer of an extruded polystyrene XPS to incorporate channels for different water or air ducts, a first oriented strand board OSB, an insulating core extruded polystyrene XPS, a second oriented strand board OSB, and a sheet of plasterboard.
 11. The enclosure according to claim 1, wherein further comprising a plurality of corners coupled at the corners of the enclosure, the corners having side through holes to facilitate tasks of hoisting and anchoring of the enclosure. 